Bulk container

ABSTRACT

A waste dust containment system includes a bag and a waste-dust fill chute. The bag is formed to include an interior region for storing dust. The waste dust fill chute conveys waste dust generated in a factory into the interior region of the bag. Once filled with wasted dust, the bag is delivered to a waste-dust disposal site away from the factory.

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/078,959 filed Jul. 8, 2008, which is expressly incorporated by reference herein.

BACKGROUND

The present disclosure relates to waste dust management, and particularly to a waste dust containment system. More particularly, the present disclosure relates to flexible intermediate bulk containers used in waste dust containment systems.

Bulk containers are used to collect waste material such as waste dust and transport that material from a warehouse, manufacturing facility, or other industrial plant to a waste-dust disposal site. One example of a bulk container is a flexible intermediate bulk container (FIBC). This container is made of a flexible material and is used, for example, to collect waste dust generated in industrial plants associated with foundry, refractory, steel, and ceramics industries.

SUMMARY

A waste dust containment system in accordance with the present disclosure includes a bag formed to include a dust-entry port opening into an interior region. The bag is configured to store waste dust discharged into the interior region through the dust-entry port from a waste delivery system

In illustrative embodiments, the bag is formed to include a rake-access inlet that is separate from the dust-entry port. A rake-access inlet closure is coupled to the bag and configured to provide means for opening and closing the rake-access inlet while waste dust is being discharged into the interior region of the bag through the dust-entry port.

In illustrative embodiments, the waste dust containment system further includes a dust rake extending into the interior region of the bag through the opened rake-access inlet while waste dust is being discharged into the interior region of the bag through the dust-entry port. The dust rake is arranged to be moved back and forth by a technician standing next to and outside of the bag to permit raking and flattening of a waste dust heap that has accumulated in the interior region of the bag under the dust-entry port.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the accompanying figures in which:

FIG. 1 is perspective view of a waste dust containment system in accordance with the present disclosure coupled to a waste delivery system, with portions of a bag included in the waste dust containment system broken away to show waste dust that has collected in an interior region of the bag;

FIG. 2 is a perspective view similar to FIG. 1 showing that a technician has opened a rake-access inlet formed in the bag and inserted a dust rake into the interior region of the bag while waste dust is being discharged into the interior region so that the dust can be raked and leveled as suggested in FIGS. 5, 7, and 9;

FIG. 3 is an enlarged perspective view of a portion of the waste dust containment system showing a closure (e.g., zipper) coupled to the bag and arranged normally to close the rake-access inlet formed in the bag;

FIG. 4 is a view similar to FIG. 3 showing that a sliding piece included in the closure has been moved from right to left two separate two zipper tracks also included in the closure to open the rake-access inlet so that a technician can insert a dust rake into the interior region of the bag as suggested in FIGS. 2 and 7;

FIG. 5-9 illustrate use of a dust rake included in the waste dust containment system to rake dust in the bag while dust is being discharged by the waste delivery system into the interior region of the bag;

FIG. 5 is a sectional view of the waste dust containment system taken along line 5-5 of FIG. 1;

FIG. 6 is a partial side elevation view taken along line 6-6 of FIG. 5 showing the closure in a closed state;

FIG. 7 is a sectional view similar to FIG. 5 showing a handle of the dust rake extending through an opened rake-access inlet and suggesting back-and-forth motion of the rake under the control of a technician to level a heap of waste dust that has accumulated in the center of the interior region of the bag under a first waste-dust fill chute included in the waste dust containment system and coupled to the bag;

FIG. 8 is a view similar to FIG. 6 taken along line 8-8 of FIG. 7 showing the closure in an opened state and showing the handle of the dust rake in the opened rake-access inlet;

FIG. 9 is a sectional view similar to FIGS. 5 and 7 showing a flattened or leveled pile of waste dust in the bag after the dust rake has been removed and the rake-access inlet has been closed;

FIG. 10 is a partial side elevation view taken along line 10-10 of FIG. 9 showing the closure now returned to a closed state;

FIG. 11 is a partial perspective view of a waste dust container system in accordance with another embodiment of the present disclosure showing a rake-access inlet closure comprising a series of snaps mounted on a foldable narrow upper strip coupled to a bag and a series of companion snap receivers mounted on a narrow lower strip coupled to the bag;

FIG. 12 is a partial perspective view of a waste dust container system in accordance with yet another embodiment of the present disclosure showing a rake-access inlet closure comprising a series of snaps mounted on a foldable wide strip coupled to a bag and a series of companion snap receivers mounted on a narrow lower strip coupled to the bag; and

FIG. 13 is an exploded perspective view showing the waste dust container system of FIG. 1 above a bag holder included in the waste dust containment system and sized to hold the bag.

DETAILED DESCRIPTION

A waste dust containment system 10 in accordance with one embodiment of the present disclosure includes a bag 12 formed to include an interior region 14 and a rake-access inlet 16 opening into interior region 14, a first waste-dust fill chute 18 coupled to bag 12 at a first waste-dust entry port 19 formed in bag 12, and a rake-access inlet closure 20 coupled to bag 12 as suggested in FIGS. 1 and 2. Rake-access inlet closure 20 is configured to be operated by a technician 100 to open and close rake-access inlet 16 during discharge of waste dust 24 into interior region 14 of bag 12 through first waste-dust entry port 19 as suggested in FIGS. 5-8. An illustrative rake-access closure 20 is a zipper as suggested in FIGS. 1-10 and other illustrative closures 120, 220 comprising snaps are suggested in FIGS. 11 and 12.

A dust rake 26 also included in waste dust containment system 10 can be extended into interior region 14 of bag 12 through an opened rake-access inlet 16 by technician 100 while waste dust 24 is flowing into interior region 14 and then moved back and forth in directions 101, 102 as suggested in FIGS. 7 and 8 to rake and flatten a heap of waste dust 24 that has accumulated in interior region 14 of bag 12 under first dust-entry port 19. Use of dust rake 26 during flow of waste dust 24 into bag 12 to flatten and perhaps compact waste dust 24 accumulating in interior region 14 of bag 12 will maximize the fill capacity of bag 12.

In an illustrative embodiment, as suggested in FIGS. 1, 2, 5, 7, and 9, a first waste-dust fill chute 18 is coupled to bag 12 at a first dust-entry port 19 formed in bag 12. First waste-dust fill chute 18 is adapted to mate with a waste delivery system 11 to allow waste dust 24 discharged by waste delivery system 11 to flow into interior region 14 of bag 12 through first dust-entry port 19. It is within the scope of the present disclosure to use any suitable means to admit waste dust 24 into interior region 24 of bag 12.

Bag 12 includes a basin 28 formed to include a waste-dust reservoir chamber 30 and a basin cover 32 coupled to basin 28 along a cover seam 34 to overlie waste-dust reservoir chamber 30. Basin cover 32 cooperates with basin 28 to form interior region 14 therebetween as suggested in FIGS. 1, 2, and 5. Basin cover 32 is formed to include first dust-entry port 19 as suggested in FIG. 1. Rake-access inlet 16 is formed in bag 12 to extend along a portion 341 of cover seam 34 in an illustrative embodiment shown in FIGS. 2 and 4.

In an illustrative embodiment shown in FIGS. 1, 2, and 7, a second waste-dust fill chute 38 is coupled to bag 12 at a second dust-entry port 39 formed in basin cover 32 of bag 12. Second waste-dust fill chute 38 is adapted to mate with waste delivery system 11 to allow waste dust 24 discharged by waste delivery system 11 also to flow into interior region 14 of bag 12 through second dust-entry port 39. Second dust-entry port 39 is located between first dust-entry port 19 and rake-access inlet 16 as suggested in FIGS. 2 and 7.

Basin 28 includes a floor 280 and in series, first, second, third, and fourth side-wall panels 281, 282, 283, and 284 that cooperate (in an illustrative embodiment) to form endless side wall 285. Each of side-wall panels 281-284 is coupled to floor 280 along a floor seam 40 and to basin cover 32 along cover seam 34 to cause rake-access inlet 16 to lie above and in spaced-apart relation to floor 280 of basin 28 as suggested in FIGS. 2 and 7. Basin 28 is made of a flexible material in an illustrative embodiment.

In an illustrative embodiment, first side-wall panel 281 is coupled to one edge of basin cover 32 along a first portion 341 of cover seam 34 and second side-wall panel 282 is coupled to a second edge of basin cover 32 along a second portion 342 of cover seam 34 as suggested in FIG. 13. Third side-wall panel 283 is coupled to a third edge of basin cover 32 along a third portion 343 of cover seam 34 and fourth side-wall panel 294 is coupled to a fourth edge of basin cover 32 along a fourth portion 344 of cover seam 34.

Endless side wall 285 is arranged to interconnect floor 280 and the basin cover 32 and coupled to basin cover 32 at cover seam 34 as suggested in FIG. 1. Fourth side-wall panel 284 is coupled to first side-wall panel 281 as suggested in FIGS. 3 and 5. Each of first and third side-wall panels 281, 283 has a short width W1 as measured between adjacent second and fourth side-wall panels 282, 284 as suggested in FIG. 13. Each of second and fourth side-wall panels 282, 284 has a relatively longer long width W2 as measured between adjacent first and third side-wall panels 281, 283 as suggested in FIG. 13. Rake-access inlet 16 is formed along portion 341 of cover seam 34 located between basin cover 32 and first side-wall panel 281.

Rake-access inlet closure 20 is coupled to bag 12 as suggested in FIGS. 3 and 4. Rake-access inlet 20 is configured to provide means for opening rake-access inlet 16 while waste dust 20 is flowing into interior region 14 of bag 12 through first dust-entry port 19 to receive a waste-dust rake 26 in rake-access inlet 16 to allow technician 100 to move waste-dust rake 26 relative to bag 12 to level a heap of waste dust 24 that has accumulated in interior region 14 of bag 12 under first dust-entry port 19 formed in bag 12 and for selectively closing rake-access inlet 16 after removal of dust rake 26 from interior region 14 formed in the bag 12 to limit discharge of waste dust 24 from bag 12.

Rake-access inlet closure 20 includes a first zipper track 21 coupled to first side-wall panel 281 and arranged to border rake-access inlet 16, a second zipper track 22 coupled to basin cover 32 and arranged to border rake-access inlet 16, and a sliding piece 23 in an illustrative embodiment as suggested in FIGS. 1 and 2. Sliding piece 23 is coupled to each of first and second zipper tracks 21, 22 for movement relative to bag 12 along portion 341 of cover seam 34 in one direction D1 as suggested in FIG. 4 to mate first and second zipper tracks 21, 22 to close rake-access inlet 16 and in an opposite second direction D2 as suggested in FIG. 3 to unmate first and second zipper tracks 21, 22 to open rake-access inlet 16.

Bag 12 is configured to minimize the amount of waste dust 24 that is released into the air surrounding bag 12. Waste dust 24 enters interior region 14 of bag 12 through chutes 18, 38 (or any other suitable means). While in operation, the only access to waste dust 24 in interior region 14 is through an opened rake-access inlet 16. Rake-access inlet closure 20 can be operated by technician 100 to allow limited access to waste dust 24 in interior region 14 so that waste dust 24 can be raked using a dust rake 26 extending into interior region of bag 12 through an opened rake-access inlet 16.

As suggested in FIGS. 2 and 7, dust rake 26 includes a rake head 261 and a handle 262 coupled to rake head 261. Handle 262 is configured to provide means arranged to extend through rake-access inlet 16 for moving rake head 261 back and forth in interior region 14 to level a heap of waste dust 24 accumulated in interior region 14 while waste dust 24 is flowing into interior region 14 through (at least) first dust-entry port 19 and first and second zipper tracks 21, 22 are at least partly unmated to open rake-access inlet 16 as suggested in FIGS. 2, 7, and 8.

In use, on some occasions, a heap of waste dust 24 can form in interior region 14 of bag 12 under first dust-entry port 19 as suggested in FIG. 5. Technician 100 can use closure 20 to open rake-access inlet 16 as suggested in FIGS. 4, 7, and 8 while waste dust 24 is flowing from waste dust delivery system 11 into interior region 14 of bag 12. Closure 20 provides access to bag 12 while bag 12 is being filled. This permits technician 100 to insert dust rake 26 into bag 12 and rake and flatten a heap of waste dust 24 while waste dust 24 continues to flow into interior region 14 of bag 12. More capacity is created in bag 12 to allow interior region 14 to be filled to the top and thus maximize use of interior region 14 and fill capacity. Once bag 12 is full, chutes 18 and 38 are tied shut with durable polypropylene straps. Transport of a filled bag 12 to a remote bag-disposal site is facilitated by filling a bag 12 while it is located in a bag carrier 112 as suggested in FIG. 13.

In other illustrative embodiments, a rake-access inlet closure 220 in accordance with the present disclosure comprises a series of snaps located along rake-access inlet 16 as shown, for example, in FIGS. 11 and 12. These snaps can be opened and closed by technician 100 to open and close rake-access inlet 16.

A bag 212 is formed to include a rake-access inlet 16 as suggested in FIG. 11. Bag 212 is coupled to a rake-access inlet closure 220 in accordance with another embodiment of the present disclosure. Rake-access inlet closure 220 includes a separable retainer snap 223 coupled to a basin cover 232 and to first side-wall panel 281 to close the rake-access inlet 16 as suggested in FIG. 11. It is within the scope of this disclosure to use one or retainer snaps or other suitable fasteners to close rake-access inlet 16 temporarily.

Basin cover 232 includes a top wall 232T formed to include first dust-entry port 19 and a foldable flap 232F coupled to top wall 232T. Top wall 237 of basin cover 232 is coupled to first, second, third, and fourth side-wall panels 281, 282, 283, and 284 at cover seam 34. Retainer snap 223 includes a first snap element 221 coupled to first side-wall panel 281 and a second snap element 222 coupled to foldable flap 232F to move therewith relative to first side-wall panel 281 and configured to mate with first snap element 221 to retain foldable flap 232F in a position closing rake-access inlet 16.

A bag 312 is formed to include a rake-access inlet 16 as suggested in FIG. 12. Bag 312 includes a basin cover 332 including top wall 232T and a foldable flap 332F coupled to top wall 232T along portion 341 of cover seam 34. Separable retainer snap 223 is coupled to first side-wall panel 281 and foldable flap 332F. Foldable flap 332F has a first length L1 that is relatively greater than a second length L2 of foldable flap 232F as suggested in FIGS. 11 and 12.

Each of bags 12, 212, and 312 is made of a flexible material and is suitable for use in a flexible intermediate bulk container (FIBC) unit. Such units are configured to be collapsed and folded, when empty, to permit the volume of the unit to be reduced for easier handling and storage.

An FIBC unit typically includes a single access that permits the unit to be filled with waste material. Often this access point is positioned in a manner that causes material to accumulate in the unit in a way that does not fill the entire volume of the unit effectively. Waste materials stored and transported in FIBC units include granular materials formed as by-products of industrial processes. FIBC units capture dust, debris, and other waste material formed during industrial and manufacturing processes, e.g., casting of metals and milling and machining of wood, steel, ceramics, and other refractory materials

In illustrative embodiments, rake-access inlet 16, when opened, permits a technician, e.g., a mill worker, to insert a dust rake 26 such as a rake, hoe, or other leveling device into interior region 14 of bag 12, 212, or 312 while waste dust 14 is flowing into interior region 14. The technician may smooth, level, flatten, and otherwise arrange waste dust 24 in interior region 14 to use fully the capacity of bag 12, 212, or 312.

In illustrative embodiments, rake-access inlet 16 has a cross-sectional area that is sized to receive rake head 261 of dust rake 26 therein. Such area may be round-, oblong-, square-, or rectangle-shaped.

In illustrative embodiments, closure 20 and 220 is configured to limit access to interior region 14 via rake-access inlet 16. This, in turn, restricts flow of waste dust 24 that may be emitted from interior region 14 when interior region 14 is filled with waste dust 24.

In an illustrative embodiment, rake-access inlet closure 20 is configured to reduce the accessible portion of area of rake-access inlet 16 by at least about 50% when in its closed position. The closed position is the position where the least amount of material would be able to be emitted from container 100. Illustratively, but not necessarily, closure 20 includes a sealable device. Examples of sealable devices that are suited for use in closure 20 include, but are not limited to, zippers, snaps, buttons, hook-and-loop fasteners, and frictional-fit type fasteners (e.g., ZIPLOC® fasteners), among others. These may be installed monolithically with rake-access inlet 16, as illustrated in FIG. 1. In other illustrative embodiments, however, rake-access inlet closures in accordance with the present disclosure may be located remote from rake-access inlet 16. Such remote-type sealable devices may include flaps and/or other pieces of material that can be positioned and secured to reduce the accessible area of rake-access inlet 16 by at least about 50%. In still other embodiments a closure may be removably secured to the bag so as to permit it to be detached from the bag in order to expose all of, or a portion of rake-access inlet 16. These types of devices could then be secured to a bag with some type of fastener (e.g., snaps, buttons, hook-and-loop fasteners) in order to reduce the exposed portion of rake-access inlet 16 and restrict the number of particles emitted from the bag. 

1. A waste dust containment system comprising a bag formed to include an interior region and a rake-access inlet opening into the interior region, a first waste-dust fill chute coupled to the bag at a first dust-entry port formed in the bag and adapted to mate with a waste delivery system to allow waste dust discharged by the waste delivery system to flow into the interior region of the bag through the first dust-entry port, and a rake-access inlet closure coupled to the bag and configured to provide means for opening the rake-access inlet while waste dust is flowing into the interior region of the bag through the first dust-entry port to receive a waste-dust rake in the rake-access inlet so that a technician can move the waste-dust rake relative to the bag to level a heap of waste dust that has accumulated in the interior region of the bag under the first dust-entry port formed in the bag and for selectively closing the rake-access inlet after removal of the dust rake from the interior region formed in the bag.
 2. The system of claim 1, wherein the bag includes a basin formed to include a waste-dust reservoir chamber and a basin cover coupled to the basin along a cover seam to overlie the waste-dust reservoir chamber and cooperate with the basin to form the interior region therebetween, the basin cover is formed to include the first dust-entry port, and the rake-access inlet is formed in the bag to extend along the cover seam.
 3. The system of claim 2, further comprising a second waste-dust fill chute coupled to the bag at a second dust-entry port formed in the basin cover of the bag and adapted to mate with the waste delivery system to allow waste dust discharged by the waste delivery system to flow into the interior region of the bag through the second dust-entry port and wherein the second dust-entry port is located between the first dust-entry port and the rake-access inlet.
 4. The system of claim 2, wherein the basin includes a floor and in series, first, second, third, and fourth side-wall panels each of which is coupled to the floor along a floor seam and to the basin cover along the cover seam to cause the rake-access inlet to lie above and in spaced-apart relation to the floor of the basin.
 5. The system of claim 2, wherein the basin includes a floor arranged to lie under and in spaced-apart relation to the basin cover and an endless side wall arranged to interconnect the floor and the basin cover and coupled to the basin cover at the cover seam, the endless side wall includes, in series first, second third, and fourth side-wall panels, the fourth side-wall panel is coupled to the first side-wall panel, each of the first and third side-wall panels has a short width as measured between adjacent second and fourth side-wall panels, each of the second and fourth side-wall panels has a relatively longer long width as measured between adjacent first and third side-wall panels, and the rake-access inlet is formed along a portion of the cover seam located between the basin cover and the first side-wall panel.
 6. The system of claim 5, wherein the rake-access inlet closure includes a first zipper track coupled to the first side-wall panel and arranged to border the rake-access inlet, a second zipper track coupled to the basin cover and arranged to border the rake-access inlet, and a sliding piece coupled to each of the first and second zipper tracks for movement relative to the bag along the cover seam in one direction to mate the first and second zipper tracks to close the rake-access inlet and in an opposite second direction to unmate the first and second zipper tracks to open the rake-access inlet.
 7. The system of claim 5, wherein the rake-access inlet closure includes a separable retainer snap coupled to the basin cover and to the first side-wall panel to close the rake-access inlet.
 8. The system of claim 7, wherein the basin cover includes a top wall formed to include the first dust-entry port and coupled to the first, second, third, and fourth side-wall panels at the cover seam and a foldable flap coupled to the top wall, and the separable retainer snap includes a first snap element coupled to the first side-wall panel and a second snap element coupled to the foldable flap to move therewith relative to the first side-wall panel and configured to mate with the first snap element to retain the foldable flap in a position closing the rake-access inlet.
 9. The system of claim 1, wherein the bag includes a floor arranged to underlie the first dust-entry port and a side wall extending upwardly from the floor and at least a portion of the rake-access inlet closure is coupled to the side wall.
 10. The system of claim 9, wherein the bag further includes a top wall formed to include the first dust-entry port and coupled to the side wall at a seam to overlie the floor and to locate the interior region therebetween and the rake-access inlet is formed in the bag to extend along a portion of the seam.
 11. The system of claim 10, wherein the rake-access inlet closure includes a first zipper track coupled to the first side-wall panel and arranged to border the rake-access inlet, a second zipper track coupled to the top wall and arranged to border the rake-access inlet, and a sliding piece coupled to each of the first and second zipper tracks for movement relative to the bag along the seam in one direction to mate the first and second zipper tracks to close the rake-access inlet and in an opposite second direction to unmate the first and second zipper tracks to open the rake-access inlet.
 12. The system of claim 9, wherein the side wall includes, in series, first, second, third, and fourth side-wall panels, the fourth side-wall panel is coupled to the first side-wall panel, each of the first and third side-wall panels has a short width as measured between adjacent second and fourth side-wall panels, each of the second and fourth side-wall panels has a relatively longer long width as measured between adjacent first and third side-wall panels, and the rake-access inlet is formed along a seam between the first side-wall panel and a portion of the bag arranged to lie above the floor and formed to include the first dust-entry port.
 13. The system of claim 1, wherein the bag includes a floor arranged to underlie the first dust-entry port and a side wall extending upwardly from the floor, the side wall includes, in series, first, second, third, and fourth side-wall panels, the fourth side-wall panel is coupled to the first side-wall panel, each of the first and third side-wall panels has a short width as measured between adjacent second and fourth side-wall panels, each of the second and fourth side-wall panels has a relatively longer long width as measured between adjacent first and third side-wall panels, and the rake-access inlet is formed along a seam between the first side-wall panel and a portion of the bag arranged to lie above the floor and formed to include the first dust-entry port.
 14. A waste dust containment system comprising a bag formed to include a first dust-entry port opening into an interior region to receive waste dust discharged from a source of waste dust and a separate rake-access inlet opening into the interior region and a rake-access closure coupled to the bag and configured normally to close the rake-access inlet, the rake-access closure includes a first zipper track coupled to a first portion of the bag bordering the rake-access inlet, a second zipper track coupled to a second portion of the bag bordering the rake-access inlet, and a sliding piece coupled to each of the first and second zipper tracks for movement relative to the bag in one direction to mate the first and second zipper tracks to close the rake-access inlet and in an opposite second direction to unmate the first and second zipper tracks to open the rake-access inlet.
 15. The system of claim 14, further comprising a dust rake arranged to extend into the interior region formed in the bag through the rake-access inlet when the rake-access inlet is opened and waste dust is entering the interior region of the bag through the first dust-entry port.
 16. The system of claim 15, wherein the dust rake includes a rake head located in the interior region of the bag and handle means coupled to the rake head and arranged to extend through the rake-access inlet for moving the rake head back and forth to level a heap of waste dust accumulated in the interior region of the bag while waste dust is flowing into the interior region of the bag through the first dust-entry port and the first and second zipper tracks are at least partly unmated to open the rake-access inlet.
 17. The system of claim 14, wherein the bag includes a basin formed to include a waste-dust reservoir chamber and a basin cover coupled to the basin along a cover seam to overlie the waste-dust reservoir chamber and cooperate with the basin to form the interior region therebetween, the basin cover is formed to include the first dust-entry port, and the rake-access inlet is formed in the bag to extend along the cover seam.
 18. The system of claim 14, wherein the bag includes a floor arranged to underlie the first dust-entry port and a side wall extending upwardly from the floor and at least a portion of the rake-access inlet closure is coupled to the side wall.
 19. The system of claim 14, wherein the bag includes a floor arranged to underlie the first dust-entry port and a side wall extending upwardly from the floor and the side wall includes, in series, first, second, third, and fourth side-wall panels, the fourth side-wall panel is coupled to the first side-wall panel, each of the first and third side-wall panels has a short width as measured between adjacent second and fourth side-wall panels, each of the second and fourth side-wall panels has a relatively longer long width as measured between adjacent first and third side-wall panels, and the rake-access inlet is formed along a seam between the first side-wall panel and a portion of the bag arranged to lie above the floor and formed to include the first dust-entry port. 